Back on the Road

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
So I purchased an my first TDI about a month ago an 03 Jetta with 190K miles questionable last timing belt change. Previous owner said with in past 20K miles but I went ahead and did the following as a little insurance since I will putting 1000 mile on a week over three days. I changed the timing belt water pump, rollers, new fans (previous no low speed operation possibly rebuild old), serpentine belt tensioner, main radiator hoses, fuel filter, oil filter and oil (Shell Rotella T 5W40). I also cleaned the front two sunroof drain plugs. I put in a new alternator from NAPA because I couldn't get a voltage regulator in time to rebuild the old one. I now a voltage regulator hopefully I can get it fixed and have a spare. Now my A/C doesn't work. It did before all the work. Here is what it look like at its worst.
[/url][/IMG]
[/url][/IMG]
Now I need fix the A/C, glow plugs, and figure out this random leak on the front passenger side but at least I am now driving. Additional I need to get new battery tray and a panzer plate.
Thanks everyone I not could have done that timing belt without the forum articles
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
Yeah it does feel pretty good. I also swapped my seats to leather ones. Now I can start enjoying it with some confidence that the vehicle will not leave me stranded. That timing belt really had me worried prior to changing it. Does anyone know if VW is using plastic impeller water pumps because the one removed was plastic while new one was metal?
 
Last edited:

JB05

Top Post Dawg
Joined
Oct 20, 2005
Location
Il.USA
TDI
Golf,2005,anthracite blue
My replacement water pump also has the metal impeller. I think that is what is available now.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
Turns out my acc wasn't working due to a wire being corroded. My leak was from the oil pan drain plug.
 

deejaaa

Veteran Member
Joined
Apr 15, 2007
Location
Baytown, Texas
TDI
FOR SALE, 2002 Jetta GLS, 5 speed
as far as metal vs plastic: depends on the vendor. there are 2 thoughts; plastic is OEM, less power used to turn. metal; last longer.
you will have to do the research to determine what you want. on my next, i will go plastic. been told that is best.
i have metal now, close to 100K, been no faults. but, i believe the TDI guru: plastic is what VW designed it for.
want to swap to leather too. it has better padding. it doesn't last long in our environment: humidity and heat. but i still want it.
glad you got it on the road.
there are a few good threads on GP problems. main one is the harness, simple DIY fixes can remedy that.
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
as far as metal vs plastic: depends on the vendor. there are 2 thoughts; plastic is OEM, less power used to turn. metal; last longer.
you will have to do the research to determine what you want. on my next, i will go plastic. been told that is best.
i have metal now, close to 100K, been no faults. but, i believe the TDI guru: plastic is what VW designed it for.
want to swap to leather too. it has better padding. it doesn't last long in our environment: humidity and heat. but i still want it.
glad you got it on the road.
there are a few good threads on GP problems. main one is the harness, simple DIY fixes can remedy that.
I have a new glow plug harness and glow plugs because my current one is cracked in multiple places. I just haven't install them yet because I am waiting on my replacement battery box to come in.

The jetta ran pretty good this weekend on my 1100 my trip from Friday to Monday, but I got an overboost condition then limp mode. It appears that my actual boost would not regulate to 1.9 bar at full throttle but would stay at 2.2 bar or higher. I have new vacuum lines that I had planned to replace later but it appears this will be moving up the priority list.

Updated:
Following the troubleshooting guide for overboost/limp mode.
I unplugged the MAF and no over boost. Vehicle would regulate to the correct boost level at full throttle with MAF disconnected. I cleaned the MAF last night and will check today if it fixed the problem. The one thing I didn't do was very it would still overboost prior to disconnecting the MAF last evening.

Another update:
Hooked up MAF this afternoon and it went into limp mode again. Just for my sanity a unplugged it again and no limp mode or overboost no matter how long I held full throttle in 4th or 5th so I guess this means my MAF is bad???
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
Update
Based on another members tip I did some additional troubleshooting on my overboost problem prior to replacing my MAF with my mityvac. When I remove my the hose from the vac on the N75 valve I get the appropriate amount of vacuum. I then connect to hose going to the n75 actuator it starts to move at 3-5 inHg but it doesn't hold vacuum and I have to continue to pump it. It appears that either I have a leak in the hose or will need a new N75 actuator. Hopefully this evening I can get my mityvac on the actuator to rule out the hose.
As a side note does anyone near 31404 have a known good MAF I can use as a second check prior to purchasing a new one.
Update 10/8
Well I replaced the vacuum line fron the N75 to the actuator. While I had the vacuum line of I checked the actuator and it would not hold a vacuum. Additionally after I attached the new vacuum line, I executed the N75 test with my VAGCOM and I could see the level move from one direction to another. It looks like I need a new VNT actuator which I will be ordering. I am a little skeptical if that will solve my issue. Fingers crossed.
Update 10/12
I fixed my broke glow plug harness and replaced the glow plugs, so far no more glow plug faults. I am making some progress.

 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I got my new VNT actuator from idparts installed last night, the lever on the turbo moves fine, vanes don't appear to be sticking. I adjusted everything per the TSB. :) So here is were the fun starts I got up early this morning, 0500 in order to test out my new VNT to see if it solved my overboost problem prior to going to work. I get the vehicle off jack stands. Crank the vehicle it starts as I am bagging down the driveway, it dies notstrange noises of anything almost like someone cut off the fuel or ignition. I try to start it a few times I get RPM movement on the tach but no joy. I push it back up the driveway which is a slight incline. The first think I think is did my timing belt break or jump a tooth. I know over dramatic. I pulled the timing cover and but the transmission in N so that I can turn the engine by hand to check the belt and timing. The IP and crank were both still aligned. I even used a mirror to verify IP alignment whole, but I didn't check the camshaft yet. My last fill up was 494 miles ago. My timing belt and fuel filter change was completed ~3000 miles ago and I was on the green line on the VAGCOM. I hooked up the VAGCOM and the only thing there was something pending about injection window I will update with the actual code when I get home. Hopefully it is something simple and cheap. As a side note I did remove the battery cable this morning and reinstall it. So I need to check for fuel going into and out of the IP at the injectors. I am not sure which no start section to use. Should I use the one about driving then dies or just crank but no run.
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I did some troubleshooting on my no start using the information provided and it looks like my IP died. :) I found one reasonably local that is being shipped to me hopefully by Friday I will be up and running. After I finished troubleshooting I decided to clean my intake and EGR. It wasn't as clogged as some of the ones I have seen on here but it definitely needed.



I also started install my panzer plate. To be continued.
 
Last edited:

Drunken_Unicorn

Well-known member
Joined
Jun 16, 2015
Location
Idaho
TDI
'05 Jetta Wagon
I am not looking forward to cleaning my intake and EGR... Bigger jobs to tackle at this time lol

I look forward to seeing some install info for your panzer plate. I'm thinking about getting one for my Jetta soon!
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I got the replacement IP installed last night after verify all timing in good order. While i was there I also replaced the thermostat and its housing and a couple of vacuum hoses that looked rough. Everything fired up after priming the new fuel filter, IP, and bleeding the injectors. I also noticed my driver's CV axle boot is torn and I need another passenger rear caliper. Hopefully get the front end back together this evening because I also replaced my AC receiver dryer and get my cv axles pulled or should I wait until I have more time.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
This morning I was able to drive the Jetta, finally. I checked my timing and it seems to be advanced quite a bit but still inside the normal range. I also checked my boost cmd vs actual and it seems that the cmd vs actual is out of wack at full throttle. I don't let it go into limp mode this time since I was on my way to work, more to come. I did some logging today and it looks like the actuator resolved my overboost/limp mode issue. The cmd vs actual that I thought was out of wack was me not giving the computer time to work. Since I purchased the vehicle this has been the first time I can use all of my go pedal. Thanks everyone for the information on the forum. More to come. I forgot to add that I recharged my AC after changing my high pressure valve and my receiver dryer so I now also have AC just in time for winter.
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I am not looking forward to cleaning my intake and EGR... Bigger jobs to tackle at this time lol

I look forward to seeing some install info for your panzer plate. I'm thinking about getting one for my Jetta soon!
The panzer plate was a fairly easy install except the passenger side front mount due to my inter cooler bracket being in the way which I had to bend in order to get my wobble extension on the bolt. I didn't take pictures during the install because i always forget unless someone reminds me, but I will get a couple in order to show you later.

I did some logging of my cmd vs actuall boost. I thought it would trip overboost but didn't, maybe the actuator fixed this issue hopefully I can get the data posted this week. I also got my first official 700+ mile tank with pic. :)

The road was wet for portions of the trip and I used AC which I haven't been able to do because it didn't work. Jetta seems to be running good even with the new to me 11mm pump. I can't really tell if there is any power difference because I was fighting the overboost prior to needing to replace the IP.
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
So I got around to logging some data, I am not sure if everything is operating per spec. I will try to add a chart but for some reason I can't post picture right now here is the data. Everything was going well then I got another random limp mode. Should I adjust my actuator more but I did the adjustment based on the TSB. :-(

Group A: '011
Engine Speed Boost Boost Charge Pressure
TIME (G28) Specified Actual (N75) Solenoid
STAMP /min mbar mbar %
0.38 1470 999.6 989.4 37.5
1.48 1491 1142.4 1009.8 29.9
2.6 1596 1764.6 1264.8 30.3
3.71 1743 1846.2 1662.6 40.2
4.82 1911 1938 2009.4 53
5.92 2058 1948.2 2244 68.1
7.01 2226 1948.2 2335.8 78.9
8.09 2373 1948.2 2346 89.3
9.17 2499 1948.2 2274.6 94
10.25 2625 1948.2 2172.6 93.6
11.33 2751 1948.2 2009.4 91.6
12.41 2856 1948.2 1683 77.3
13.49 2940 1948.2 1479 66.5
14.57 3024 1948.2 1570.8 66.5
15.65 3108 1948.2 1652.4 66.5
16.73 3213 1948.2 1713.6 67.3
17.81 3318 1948.2 1774.8 66.9
18.89 3423 1948.2 1846.2 64.9
19.97 3528 1948.2 1887 64.5
21.05 3612 1948.2 1907.4 64.9
22.13 3717 1948.2 1927.8 64.5
23.21 3801 1948.2 1927.8 64.5
24.29 3885 1948.2 1927.8 65.7
25.37 3969 1948.2 1938 65.7
26.45 4053 1938 1938 66.5
27.53 4116 1917.6 1927.8 67.3
28.61 2814 1030.2 1122 60.6
29.69 3003 1040.4 1020 53.4
94.11 1911 1009.8 999.6 40.2
95.22 1911 1081.2 999.6 44.6
96.34 1953 1448.4 1193.4 33.9
97.43 2079 1897.2 1693.2 37.5
98.51 2226 1948.2 2131.8 59
99.59 2373 1948.2 2315.4 74.5
100.67 2499 1948.2 2335.8 84.5
101.75 2625 1948.2 2274.6 90.4
102.83 2730 1948.2 1989 86.5
103.91 2835 1948.2 1642.2 70.5
104.99 2898 1948.2 1560.6 65.3
106.07 2982 1948.2 1672.8 66.5
107.15 3066 1948.2 1734 66.5
108.23 3150 1948.2 1785 64.9
109.31 3234 1948.2 1856.4 64.1
110.39 3318 1948.2 1907.4 64.1
111.47 3381 1948.2 1907.4 63.4
112.55 3465 1948.2 1927.8 63.8
113.63 3528 1948.2 1938 63.8
114.71 3591 1948.2 1938 63.8
115.79 3654 1948.2 1938 64.5
116.89 3717 1948.2 1938 64.9
117.97 3759 1948.2 1938 64.9
119.06 3822 1948.2 1938 64.9
120.13 3885 1948.2 1948.2 65.7
121.21 3927 1948.2 1938 66.1
122.3 3969 1948.2 1938 66.5
123.37 4011 1948.2 1948.2 66.5
124.47 4011 1091.4 1744.2 94.4
125.56 2583 1020 1071 57.4
126.64 2961 1040.4 1040.4 51
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I replaced my rear passenger caliper, pads, and flushed all the all the old brake fluid out of the system man was that stuff ugly. I don't think that fluid had been changed in years.
I also swapped my EGR and N75 valve with no change in turbo performance. I also recheck my turbo actuator adjustment which seemed a little off but I think I may have the rod a little long vs a little short and check for overboost which didn't happen surprise surprise. I preceded on another one of my 1200 mile trips. Unfortunately 4 hours into the trip I got hit be a deer, luckily Bambi didn't do a lot of damage that her and her family could have done. She took out my drivers headlight, crushed part of hood and fender where they meet the headlight. I was able to make it to my destination with only one headlight. My return trip will be in the daylight so all should be fine until I get home and deal with insurance.
 

deejaaa

Veteran Member
Joined
Apr 15, 2007
Location
Baytown, Texas
TDI
FOR SALE, 2002 Jetta GLS, 5 speed
..........4 hours into the trip I got hit be a deer, luckily Bambi didn't do a lot of damage that her and her family could have done. She took out my drivers headlight, crushed part of hood and fender.......
exact reason I'm putting a 60w spot LED with 5100 lumens up front. I will be driving at midnight for 3 months starting next month. only difference is we have wild hogs.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I finally got the jetta back together new paint, hood, fender, and headlights from Jeff

 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
looks good.
Thanks I have a question when I installed the new to me 11mm pump, everything went fine. The timing looked good and it has been driving fine. Is there anything that I should adjust since I am possibly flow more fuel ~20% from what I have read. I get a little smoke if I WOT but my FE doesn't seem to be affect much by the IP, then to I only drove a few thousand miles before my IP died which in the Jetta is on what 4-5 fill ups so I only have a few fill ups with the 10mm IP. I seem to be averaging 40-45 mpg on the highway at speeds 75-90 mph indicated.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I have made it to 233k miles without any major issues since I met a deer on the highway. It is time for new tires(Continental True Contact supposedly 90k mile tires) but while waiting to for them to arrive I noticed that my tie rod ends are toast. I have been planning on doing a suspension refresh since I bought the vehicle but have been putting it off. So far it is gone okay the control arms came out pretty easy but I ended have to cut the nuts off the tie rod ends. I suspect those ends are original. The strange thing is the drivers side bushings on the control arm look great but the passenger side are toast. Hopefully I can get the refresh completed this weekend and my new to me st coil overs installed. If the coil overs suck I will just go back to an oem style setup and sell the coils. As a side note thanks to everyone who takes pictures of their work because I rarely remember, until I am almost finished.
 
Last edited:

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I got the suspension refresh completed but I am not happy with the coils. I will be going back to a more OEM setup but as a side note tonight I installed a .658 5th gear due the excessive highway driving I am doing currently. If anyone is interest in a set of ST Coilovers I will have some for sell shortly.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I ending up going with Suplex Springs and Optimal Shocks and struts. These seem to work best for my 9 hour drives every week on the interstate. I think I have given up a little performance but I don't feel as beat up after my 9 hour run last night. As a side note I have no idea how these cars feel with OEM suspension because when I purchased the vehicle the vehicle had 194k miles on it with the original shocks and struts. Additionally it doesn't seem like my skid plate is getting beat up as much. I forgot to add that I put the .658 5th gear so that may have contributed to me not being up.

The RMT100 is a nice radio. I tested out last night on my 9 hour drive and all functions work well for me. I test playback via Aux and bluetooth. The radio paired with my phone easily. I placed and received several calls with radio. The quality seems acceptable but I will have to complete more evaluation because one caller seem to have trouble understanding me but I am not sure if the issue was cell reception.
 
Last edited:

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
Radio

The RMT100 is a nice radio. I tested out last night on my 9 hour drive and all functions work well for me. I test playback via Aux and bluetooth. The radio paired with my phone easily. I placed and received several calls with radio. The quality seems acceptable but I will have to complete more evaluation because one caller seem to have trouble understanding me but I am not sure if the issue was cell reception.
I installed a Kenwood radio with NAV, Phone, DVD, Delirious radio & such.
Got a smoking deal as open box for Best Buy. Less then 1/2 price after buying the missing pieces.

I also replaced the rear speakers as 1 was fried by the dealer. :(

What a difference the sound is (even FM) over the Monsoon.

Rich W.
 

cbman18j

Veteran Member
Joined
May 29, 2015
Location
Savannah
TDI
03 Jetta TDI (First Diesel)
I was considering going with an aftermarket radio but wanted a factory looking option. I had a monsoon before but oddly the RMT-100 sounds better to me than the original headunit.

I installed a Kenwood radio with NAV, Phone, DVD, Delirious radio & such.
Got a smoking deal as open box for Best Buy. Less then 1/2 price after buying the missing pieces.

I also replaced the rear speakers as 1 was fried by the dealer. :(

What a difference the sound is (even FM) over the Monsoon.

Rich W.
 

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
I was considering going with an aftermarket radio but wanted a factory looking option. I had a monsoon before but oddly the RMT-100 sounds better to me than the original headunit.
The Monsoon wasn't bad but no comparison to newer radios.
HD radio is great if you get it.
Some areas by me I do not get it.
Going to work I do.

Rich W.
 

JohnnyTDR

Active member
Joined
Sep 20, 2006
Location
Berkley, MI
TDI
'89 Transporter DoKa Syncro
The RMT100 is a nice radio. I tested out last night on my 9 hour drive and all functions work well for me. I test playback via Aux and bluetooth. The radio paired with my phone easily. I placed and received several calls with radio. The quality seems acceptable but I will have to complete more evaluation because one caller seem to have trouble understanding me but I am not sure if the issue was cell reception.
Any tips on how you sorted out the installation? I've been trying to figure it out on my B5 Passat for a while now...
 
Top